Total solder points: 82

Difficulty level:
beginner 1 2 3 4 5 advanced
Dc to Pulse Width Modulator
ILLUSTRATED ASSEMBLY MANUAL H8004IP-2
Hardware:


PWM range: 0 to 100%
PWM frequency: 100 to 5000Hz adjustable
Minimum PWM offset: 0 to 20% adjustable
Adjustable sensitivity: 2.5 to 35VDC
Short circuit protection
Overload protection: 6.5A
Under-Voltage lockout: 7VDC typ.
Soft start
Power Supply: 8 to 35VDC unregulated
Supply current (No load): 35mA typ
Efficiency: better than 90% at full load
Dimensions (wxdxh): 85 x 48 x 45mm
K8004
2
VELLEMAN Components NV
Legen Heirweg 33
9890 Gavere
Belgium Europe
www.velleman.be
www.velleman-kit.com
3
1. Assembly (Skipping this can lead to troubles ! )
Ok, so we have your attention. These hints will help you to make this project success-
ful. Read them carefully.

1.1 Make sure you have the right tools:

A good quality soldering iron (25-
40W) with a small tip.

Wipe it often on a wet sponge or cloth, to keep it clean; then apply solder to the
tip, to give it a wet look. This is called thinning and will protect the tip, and
enables you to make good connections. When solder rolls off the tip,
it needs cleaning.

Thin raisin-core solder. Do not use
any flux or grease.

A diagonal cutter to trim excess wires. To avoid injury
when cutting excess leads, hold the lead so they
cannot fly towards the eyes.

Needle nose pliers, for bending leads, or to hold components in
place.

Small blade and Phillips screwdrivers. A basic range is fine.


For some projects, a basic multi-meter is required, or
might be handy

1.2 Assembly Hints :

Make sure the skill level matches your experience, to avoid disappointments.
Follow the instructions carefully. Read and understand the entire step before you
perform each operation.
Perform the assembly in the correct order as stated in this manual
Position all parts on the PCB (Printed Circuit Board) as shown on the drawings.
Values on the circuit diagram are subject to changes.
Values in this assembly guide are correct*
Use the check-boxes to mark your progress.
Please read the included information on safety and customer service

* Typographical inaccuracies excluded. Always look for possible last minute manual
updates, indicated as NOTE on a separate leaflet.
0
.
0
0
0
Assembly hints
4
1.3 Soldering Hints :

Mount the component against the PCB surface and carefully solder the
leads







Make sure the solder joints are cone-shaped and shiny


Trim excess leads as close as possible to the solder joint










REMOVE THEM FROM THE TAPE
ONE AT A TIME !
AXIAL COMPONENTS ARE TAPED IN THE CORRECT
MOUNTING SEQUENCE !
Assembly hints

I

P

E

S
F

S

D
K

N

D

G
B

F

N
L


C

O

D

E


C
O
D
I
C
E

C
O
L
O
R
E

C
O
D
I
G
O

D
E

C
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R
E
S

C
O
D
I
G
O

D
E

C
O
L
-
O
R
E
S

V

R
I

K
O
O
D
I

F

R
G

S
C
H
E
M
A

F
A
R
V
E
-
K
O
D
E

F
A
R
G
E
-
K
O
D
E

F
A
R
B

K
O
D
E

C
O
L
O
U
R

C
O
D
E

C
O
D
I
F
I
-
C
A
T
I
O
N

D
E
S

C
O
U
-
L
E
U
R
S

K
L
E
U
R
K
O
D
E

C

O

D

E

0

N
e
r
o

P
r
e
t
o

N
e
g
r
o

M
u
s
t
a

S
v
a
r
t

S
o
r
t

S
o
r
t

S
c
h
w
a
r
z

B
l
a
c
k

N
o
i
r

Z
w
a
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t

0

1

M
a
r
r
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n
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C
a
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t
a
n
h
o

M
a
r
r

n

R
u
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k
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a

B
r
u
n

B
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u
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B
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B
r
a
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B
r
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w
n

B
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B
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n

1

2

R
o
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E
n
c
a
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n
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d
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R
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P
u
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R

d

R

d

R

d

R
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t

R
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d

R
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R
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d

2

3

A
r
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n
c
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L
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j
a

N
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d
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O
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a
n
s
s
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O
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a
n
g
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O
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a
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g
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O
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O
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g
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O
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O
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e

3

4

G
i
a
l
l
o

A
m
a
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e
l
o

A
m
a
r
i
l
l
o

K
e
l
t
a
i
n
e
n

G
u
l

G
u
l

G
u
l

G
e
l
b

Y
e
l
l
o
w

J
a
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n
e

G
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l

4

5

V
e
r
d
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V
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r
d
e

V
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d
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V
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h
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e

G
r

n

G
r

n

G
r

n
n

G
r

n

G
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e
n

V
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t

G
r
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n

5

6

B
l
u

A
z
u
l

A
z
u
l

S
i
n
i
n
e
n

B
l

B
l

B
l

B
l
a
u

B
l
u
e

B
l
e
u

B
l
a
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w

6

7

V
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a

V
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M
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P
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L
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t

P
u
r
p
l
e

V
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o
l
e
t

P
a
a
r
s

7

8

G
r
i
g
i
o

C
i
n
z
e
n
t
o

G
r
i
s

H
a
r
m
a
a

G
r

G
r

G
r

G
r
a
u

G
r
e
y

G
r
i
s

G
r
i
j
s

8

9

B
i
a
n
c
o

B
r
a
n
c
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B
l
a
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c
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V
a
l
k
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e
n

V
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t

H
v
i
d

H
v
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d
t

W
e
i
s
s

W
h
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t
e

B
l
a
n
c

W
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t

9

A

A
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g
e
n
t
o

P
r
a
t
e
a
d
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P
l
a
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a

H
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p
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S
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S

l
v

S

l
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S
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A
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g
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t

Z
i
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v
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r

A

B

O
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o

D
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a
d
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O
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K
u
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t
a

G
u
l
d

G
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l
d

G
u
l
d
l

G
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l
d

G
o
l
d

O
r

G
o
u
d

B

5
%
4
K
7
=

(

4


-


7


-


2


-


B

)
1
%
4
K
7
=

(

4

-

7

-

0

-

1

-

1

)
C
O
L
O
R
=

2

5
C
O
L
O
R
=

2
.
.
.
5

6












C1 : 100nF (104)
C2 : 100nF (104)
C3 : 100nF (104)
C4 : 100nF (104)
6. Ceramic Capacitors
C...






R1 : 220 (2-2-1-B)
R2 : 220 (2-2-1-B)
R3 : 2K2 (2-2-2-B)
R4 : 2K2 (2-2-2-B)
R5 : 10K (1-0-3-B)
R6 : 100K (1-0-4-B)
R7 : 220K (2-2-4-B)
1. Resistors
R...





IC1 : 16p
3. IC sockets. Watch the
position of the notch!
Construction















D1 : 1N4148
D2 : 1N4148
D3 : 1N4007
2. Diodes, check the
polarity
D...
CATHODE









RV1 : 10K
RV2 : 10K
RV3 : 100K
4. Trim potentiometer
RV...









Vref
5. PCB pins
7
Construction



















T1 : BC547
7. Transistor









C5 : 10F
C6 : 10F
C7 : 100F (40Vmin)
8. Electrolytic capacitors.
Check the polarity !
C...





D4 : 6A2 / 6A6
9. Diodes, check the
polarity
D...
CATHODE












J1 : 2p






J2 : 2p
J3 : 2p
10. Screw connectors










R8 : 0,22 (R22)
11. 0,5W Resistors
R...
2mm









R9 : 0,22 (R22)
R10 : 0,22 (R22)
12. 0,5W Resistors
R...
8







IC1 : 3525
14. IC. Watch the
position of the notch!
PIN 1
1
Construction


T2 : BUK555-60B or eq.
13. Transistor
10mm
M3 BOLT
LOCK
WASHER
M3
NUT
9








Fig A



































Fig B


































Fig C
Construction
10
15. PCB layout.
PCB
11
16. Schematic diagram.
Schematic diagram
12
Modifications and typographical errors reserved
Velleman Components nv.
H8004IP - 2003 - ED2